Whether it’s placed by the pool, the grill or the potting shed, this rolling storage bench is a handy way to clear clutter. It not only stores tools and accessories, but it also provides extra seating.
And, best of all, it’s made to withstand the elements…so you can leave it outside!
Skill Level: Advanced
- Sheet of 4′ x 8′ ¾″ of cabinet-grade plywood
- 10 linear feet of 2x2s
- 4 (2 ½″) locking casters
- 30″ or 36″ continuous (aka piano) hinge
- Pull handle
- Box of 1 ⅝″ or 2″ coarse-thread screws
- 16 (#12 x ¾″) wood screws
- Small container of finishing nails
- Outdoor-rated cushion size 46½″ width x 16″ depth x 4″ height
- 45″ decorative moulding “L-shaped”
- Paint or stain
- Optional: 12-14 linear feet of base moulding
- Table saw or circular saw
- Bottle of exterior wood glue
- Small container of wood filler
- Small sanding sponge fine grit
1. Cut plywood to the following dimensions: 2 (14 ½″ x 16″) pieces for the sides; 2 (46 ½″ x 16″) pieces for the front and back; and 2 (46″ x 16″) pieces for the top and bottom.
2. Assemble all pieces, except for the top, using coarse-thread screws and wood glue. Make sure the sides are flush between the front and back panels.
3. Use clamps to prevent any movement and give added strength.
4. Line up the top piece square and install the continuous hinge in the center, fastening on the back of the bench.
5. Cut the 2×2 pieces of lumber into 6 14″ lengths and 1 36″ length.
6. Place 4 of the 14″ pieces in the inside corners. Use coarse-thread screws and wood glue to install.
7. Use the remaining 2 14″ and 1 36″ pieces to form an H-shaped support underneath the top of the bench for added stability.Use coarse-thread screws and wood glue to fasten. Make sure there is at least ¾″ clearance from the front and back of the inside of the bench so the top can open and close securely.
8. Turn the bench upside down and install the 4 casters on each corner, using the #12 x ¾″ wood screws to fasten. There should be 16 screws in total to fasten all casters.
9. Turn bench back upright and install the decorative L-shaped moulding on the top front lip of the bench. Center and use finishing nails or wood glue to fasten.
10. Center and install pull handle (screws are provided) into the front middle of the bench top.
11. At this stage, you can either stain, paint, or another option — apply base moulding to hide and give panache to the base of the bench. You will need to cut a 45-degree miter to all 4 pieces, 2 in 16″ and 2 in 46 ½″ inches. (Cutting is more effectively done with a power saw, but cutting it by hand in a mitre box with a handsaw can be achieved.) The angles should be as illustrated below. Attach moulding using wood glue and finishing nails. Check and closely inspect all sides, using wood filler to fill any gaps, holes or cracks in the bench. Let dry and sand down any rough edges or excessive amounts of wood filler. Wipe and dust down. Now you are ready to stain or paint.
12. Place your cushion on top and enjoy!
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